Armor for ballistic-resistant headgear

ABSTRACT

Armor for a helmet includes a soft-armor attachment and a hard-armor attachment. The soft-armor attachment encases a flexible soft-armor anti-ballistic member within its interior, and detachably mounts to the helmet exterior using one or more fasteners. The hard-armor attachment encases one or more hard-armor members within its interior, and detachably mounts to the soft-armor attachment using one or more fasteners. When both the soft-armor attachment and the hard-armor attachment are in the mounted position, the soft-armor attachment is disposed between the helmet exterior and the hard-armor attachment.

BACKGROUND

The present invention relates generally to personal body armor and, moreparticularly, to armor for ballistic-resistant headgear.

Historically, ballistic-resistant helmets were manufactured from steelto form shallow pot-like structures that fit over a user's head. These“steel pots” were heavy and cumbersome and not very comfortable.Further, their protective abilities were, at best, limited.Technological advances, however, now enable ballistic-resistant helmetsto be manufactured from high-strength synthetic fibers such as KEVLAR.Due to its chemical structure, helmets manufactured from KEVLAR are muchstronger and lighter than steel, and also are remarkably moreheat-resistant than steel. As such, KEVLAR helmets provide a user withprotection superior to that provided by steel.

Military and law enforcement personnel routinely face situations inwhich their survival depends upon the ability of a helmet to deflectvarious projectiles such as bullets, shrapnel, and other debris. Whilethe conventional helmets mentioned above provide at least some measureof protection, they are typically not strong enough to deflect or stopall types of ballistic objects. For example, very high-speedprojectiles, such as bullets and shrapnel, have been known to breachboth steel pots and KEVLAR helmets. Future advances may producematerials having even more superior anti-ballistic characteristics, butthey are likely to be very costly. Even if such a material werecurrently available, large-scale replacement of existing inventory wouldindeed prove prohibitively expensive. Therefore, what is needed is amethod and system that will quickly and easily allow users to enhancethe ballistic-resistant qualities of their currently available helmets.

SUMMARY

According to the present invention, one or more armor members may beemployed to provide conventional ballistic-resistant helmets withincreased anti-ballistic protection. In one embodiment, a first armormember comprises a soft-armor attachment that detachably connects to theuser's helmet. One or more corresponding mechanical fasteners, such assnaps or zippers, may be disposed on both the soft-armor attachment andthe helmet to allow the user to connect and remove the soft-armorattachment to and from the helmet. The soft-armor attachment is formedto create an interior pocket that may contain a flexible anti-ballisticmaterial and, thus, substantially conforms to the shape of the helmetwhen connected.

In an alternate embodiment, a second armor member may further beconnected to the first armor member that is connected to the helmet. Thesecond armor member may comprise, for example, a hard-armor attachmenthaving one or more mechanical fasteners. The fasteners allow users todetachably connect the hard-armor attachment to one or morecorresponding fasteners disposed on the soft-armor attachment. As above,the hard-armor attachment is formed to create one or more interiorpockets that contain a like number of hard-armor plates, such asanti-ballistic ceramic or steel. Each of the hard-armor plates and,thus, the hard-armor attachment, is formed to substantially conform tothe shape of the helmet and the soft-armor attachment when connected.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates the armor system according to one embodiment of thepresent invention.

FIG. 2 illustrates a type of ballistic-resistant helmet that may bearmored according to one embodiment of the present invention.

FIGS. 3A-3B illustrate a soft-armor attachment that may be used to armora ballistic-resistant helmet according to one embodiment of the presentinvention.

FIGS. 4A-4B illustrate a hard-armor attachment that may be used to armora ballistic-resistant helmet according to one embodiment of the presentinvention.

FIGS. 5A illustrates a soft-armor attachment detachably connected to aballistic-resistant helmet according to one embodiment of the presentinvention.

FIG. 5B illustrates a soft-armor attachment and a hard-armor attachmentdetachably connected to a ballistic-resistant helmet according to oneembodiment of the present invention.

FIG. 6 illustrates a type of ballistic-resistant helmet that may bearmored according to an alternate embodiment of the present invention.

FIGS. 7A-7B illustrate a soft-armor attachment that may be used to armora ballistic-resistant helmet according to an alternate embodiment of thepresent invention.

FIG. 8 illustrates a soft-armor attachment and a hard-armor attachmentdetachably connected to a ballistic-resistant helmet according to analternate embodiment of the present invention.

FIG. 9 illustrates a soft-armor attachment and a hard-armor attachmentdetachably connected to a ballistic-resistant helmet according toanother alternate embodiment of the present invention.

DETAILED DESCRIPTION

Turning now to the drawings, an anti-ballistic headgear system accordingto one embodiment of the present invention is shown therein andindicated generally by the number 10. As seen in FIG. 1, system 10comprises a ballistic-resistant helmet 20, a first armored member 30,and a second armored member 50. First armor member 30 and/or secondarmor member 50 may be used alone or in combination to provide anti-ballistic protection to a user of helmet 20.

According to one embodiment of the present invention, for example, thefirst armored member 30 detachably couples to helmet 20 to protect auser's head and/or neck area against various high and low speedprojectiles including, but not limited to, bullets, fragments, secondaryprojectiles, and debris. In an alternate embodiment, the second armoredmember 50 may further be detachably coupled to the first armored member30 to provide the user with an even greater level of protection againstthe various projectiles mentioned above. The protection provided by thefirst and/or second armored members 30,50 is in addition to anyprotection that might already be provided by helmet 20.

FIG. 2 illustrates helmet 20 in more detail. Helmet 20 may be any typeof helmet known in the art that provides some measure of protection to auser's head. In one embodiment, for example, helmet 20 is a combathelmet having ballistic-resistant capabilities. One such type of helmet20 might be a helmet commonly referred to as a KEVLAR helmet. Helmetssuch as these are currently employed by both the military, and civilianlaw enforcement agencies.

Helmet 20 typically includes a chinstrap 22 that helps to maintainhelmet 20 squarely and securely on the user's head. Chinstrap 22 maycomprise, for example, a pair of straps, each fixedly attached at oneend to helmet 20. As those skilled in the art will appreciate, any of avariety of buckles or other mechanisms may be used to connect the freeends of the straps to secure helmet 20 to the user's head. Helmet 20 mayalso include a helmet cover 24 that substantially covers the exteriorsurface 26 of helmet 20. Cover 24 may be, for example, constructed of aplurality of cloth panels stitched together to fit over exterior surface26 of helmet 20. Alternatively, cover 24 may be a unitary piece ofelastic material that permits the user to stretch cover 24 over helmet20.

Cover 24 also comprises a flap 28 that is secured along one of itslengths to cover 24, for example, by stitching. Flap 28 may beconstructed of the same material used to construct cover 24, although asthose skilled in the art will appreciate, this is not required. In oneembodiment, flap 28 extends substantially around the perimeter of helmet20, and may be lifted and lowered along its length to expose and cover,respectively, one or more mechanical fasteners used to detachablyconnect the armor members 30, 50 of the present invention. When lowered,flap 28 protects against dirt, moisture, and other foreign materialsthat may compromise the integrity of the connection between helmet 20and any connected armor members. As seen in FIG. 2, the mechanicalfasteners comprise snaps 27 that may be integrally formed with cover 24or, alternatively, the exterior surface 26 of helmet 20.

FIGS. 3A and 3B illustrate the first armor member 30 as it might beconfigured according to one embodiment of the present invention. As seenin FIG. 3A, the first armor member 30 is constructed of tear-resistantfabric that may be sewn, for example, to form an interior pocket 32. Amechanical fastener, such as a zipper, may be sewn or otherwise attachedto the fabric to form an optional access opening 34 that permits accessto the interior pocket 32. The access opening 34 allows the user toinsert and extract soft armor 36 into the interior pocket 32, therebyfacilitating as-needed cleaning of first armor member 30 and/orreplacement of soft armor 36. One or more mechanical fasteners, which inFIG. 3A comprise snaps 38, are disposed adjacent a peripheral edge offirst armor member 30. Snaps 38 mate with snaps 27 disposed on helmet 20and/or cover 24 to allow the user to detachably connect the first armormember 30 to helmet 20.

FIG. 3B illustrates the opposing side of first armor member 30. In FIG.3B, an additional set of one or more snaps 40 are disposed adjacent aperipheral edge of first armor member 30. As will be described in moredetail later, snaps 40 may be coupled to corresponding snaps disposed onsecond armor member 50 to allow the user to detachably connect thesecond armor member 50 to the first armor member 30.

The soft armor 36 used in the present invention may be any soft-armorknown in the art having anti-ballistic or ballistic-resistantcapabilities. There are many types of commercially available soft armorthat would readily be suitable for use in the present invention. Forexample, in one embodiment of the present invention, soft armor 36comprises one or more layers of an anti-ballistic woven fabric known asKEVLAR. Briefly, KEVLAR is manufactured by inter-weaving high-strengtharamid fibers to form dense sheets of fabric. These sheets are highlyflexible and may be used as a weave to create various articles ofclothing, such as bulletproof vests. Alternatively, multiple sheets ofKEVLAR may be resin-bonded at high temperatures to create a harder, lessflexible product, such as helmet 20. According to the present invention,however, one or more layers of the flexible fabric sheets are insertedinto the interior pocket 32 of first armor member 30 to form theflexible soft armor 36. The flexibility of the KEVLAR fabric permits thefirst armor member 30 to substantially conform to the shape of helmet 20when it is connected.

FIGS. 4A and 4B illustrate the second armor member 50 as it might beconfigured according to one embodiment of the present invention. Likefirst armor member 30, second armor member 50 may also be constructedfrom tear-resistant fabric formed to create an interior pocket 52. Inaddition, the tear-resistant fabric may also be sewn, for example, atselected positions to partition second armor member 50 into multiplesegments 54; however, partitioning second armor member 50 into multiplesegments is not required. In this embodiment, second armor member 50 ispartitioned into three segments 54, each having an interior pocket 52and a zipper that forms an access opening 56 into the interior pockets52. As above, the access openings 56 permit a user to insert and extractone or more hard-armor members 58 into the interior pockets 52, therebyfacilitating both cleaning and replacement. One or more mechanicalfasteners, which in FIG. 4A comprise snaps 60, are disposed near theperiphery of second armor member 50 and permit the second armor member50 to be detachably connected to the first armor member 30. Moreparticularly, snaps 60 would couple to corresponding snaps 40 disposedon first armor member 30.

The hard armor 58 used in the present invention may be any hard armorknown in the art that is suitable for deflecting and/or stoppingprojectiles. This includes, but is not limited to, currently availablehard-armor constructed from materials such as steel, multiple layers ofresin-bonded KEVLAR, and ceramic. In the embodiment of FIGS. 4A and 4B,the hard armor 58 comprises a plurality of ceramic plates; however,hard-armor 58 may alternately comprise a single plate. In embodimentsthat employ multiple plates of hard armor 58, the edges of the platesmay be formed to interlock or overlap by a desired amount. One side ofeach of the ceramic plates has a concave surface that faces inwardlytoward the helmet 20. The opposing side, or strike face side, has aconvex surface that faces outwardly from the helmet 20. Theconvex/concave surfaces of hard armor 58 permit the second armor member50 to substantially conform to the shape of helmet 20.

As previously stated, both first armor member 30 and second armor member50 may be detachably connected to helmet 20. However, the presentinvention does not require using both the first armor member 30 and thesecond armor member 50. Rather, first armor member 30 and second armormember 50 may be used alone or in combination to enhance the level ofprotection provided by helmet 20 alone. The ability to connect anddetach the first and/or second armor members 30, 50 permits a user totailor the level of protection to an expected threat.

As seen in FIG. 5A, for example, only the first armor member 30 iscoupled to a rear area of helmet 20. This configuration might be usefulfor military troops or law enforcement personnel expecting a low threatlevel, such as that coincident with a riot or localized uprising. Whenconnected to helmet 20, the soft armor 36 of first armor member 30enhances the protective capabilities of helmet 20 by deflecting orblocking at least some types of high-speed projectiles that mightotherwise penetrate helmet 20.

To couple first armor member 30 to helmet 20, the user merely connectssnaps 38 on first armor member 30 to corresponding snaps 27 on cover 24.Alternatively, corresponding snaps 27 may be integrally formed on theexterior surface 26 of helmet 20. Because soft armor 36 is flexible,first armor member 30 substantially conforms to the shape of helmet 20when the two are connected. In addition, the flexibility and lightweightof first armor member 30 does not hinder or impede the user's head andneck movement.

For situations that might require an even higher level of anti-ballisticprotection, second armor member 50 may further be detachably coupled tofirst armor member 30 as seen in FIG. 5B. To connect second armor member50 to first armor member 30, the user need merely to connect snaps 60 onsecond armor member 50 to corresponding snaps 40 disposed on first armormember 30. Because second armor member 50 comprises hard armor 58, itoffers anti-ballistic protection to a level that might be required todeflect or block high-velocity projectiles that might otherwisepenetrate soft armor 36 and/or helmet 20. Particularly, hard armor 58decelerates these high-velocity projectiles upon impact and may causethe projectile to fragment. However, hard armor 58, when constructed ofceramic or like material, may likewise fracture or even shatter whenstruck by a high-velocity projectile. In these cases, soft armor 36 ofthe first armor member 30 could prevent the decelerated high-velocityprojectile and/or any resultant fragments from perforating helmet 20 andcausing serious injury or death to the user.

Those skilled in the art will realize that the snaps illustrated in thedrawings are not the only mechanical fasteners that may be used todetachably connect the first and/or second armor members 30, 50 tohelmet 20. Rather, any type of mechanical fastener known in the art issuitable for use with the present invention. FIGS. 6-8, for example,illustrate an alternate embodiment wherein a zipper 29 is sewn to cover24. Zipper 29 comprises one portion of a zipper that mates with acorresponding portion 39 disposed on the first armor member 30. Snaps 60on second armor member 50 may then be detachably coupled tocorresponding snaps 40 disposed on first armor member 30. Still otherembodiments use other types of mechanical fasteners to detachably couplefirst and/or second armor members 30, 50 to helmet 20 including, but notlimited to, screws and hook-and-loop types fasteners.

Additionally, it should be noted that the present invention is notlimited to the positioning of the first and/or second armor members 30,50 shown in the figures. Specifically, the figures illustrate thelower-most edges of first and second armor members 30, 50 as beingsubstantially flush with the lower-most edge of the rear of helmet 20.However, those skilled in the art will readily appreciate that thispositioning is for illustrative purposes only, and first and/or secondarmor members 30, 50 may be may be detachably connected to helmet 20 inany position as needed or desired. FIG. 9, for example, illustrates anembodiment where the first and second armor members 30, 50 extend belowthe helmet 20. Further, the lateral edges of the first and/or secondarmor members 30, 50 may be may extend forwardly towards the front ofhelmet 20 by any amount desired. In this position, the present inventionmay provide protection to areas of the user's head and neck typicallynot covered or protected by helmet 20. Such areas include, but notlimited to, the lower and/or side areas of the neck and/or the temporalregions of the user's head.

The specification to this point has described the armor of the presentinvention as having two separate armor modules. However, depending uponthe armor material used, the present invention may be practiced usingonly a single armor member. For example, it is known to manufacture aunitary armor member that includes both soft armor 36 and hard armor 58.One or more of these unitary armor members may then be inserted into oneof the first or second armor members 30, 50 and detachably coupled tohelmet 20. Other materials that may be suitable for use as armor membersinclude, but are limited to, steel plating and resin-bonded syntheticfibers such as KEVLAR.

In addition, the figures illustrate both the first and second armormembers 30, 50 as skirts that include optional access openings 34, 56.As used herein, a skirt is defined as an attachment that connects to aheadgear such that it wraps at least partially around a portion of theheadgear. Those skilled in the art will readily appreciate, however,that first and/or second armor members 30, 50 need not be a skirt, butinstead, may take any desired shape or form that permits the armormembers 30, 50 to detachably connect to helmet 20. Further, the accessopenings 34, 56 might be positioned at any angle and on any surface ofthe first and/or second armor members 30, 50. Additionally, while thefigures illustrate access openings 34, 56 as including zippers, anyfastening or covering mechanism known in the art may be used. Examplesof suitable fastening devices include, but are not limited to, snaps,hook and loop, flaps, and the like. Alternatively, access opening 34, 56may not include access openings at all. In embodiments that do notinclude access openings 34, 56, the fabric used to form the first and/orsecond armor members 30, 50 may be sewn around their respectiveperipheries, for example, to encase the soft armor 36 and hard armor 58within their respective interior pockets 32, 52.

Those skilled in the art will also realize that the present inventionmay be suitable for headgear other than combat helmets to provideappropriate levels of protection to their users as well. In addition,the type, material, flexibility, placement, and positioning of the armorof the present invention may be tailored to meet an expected threatlevel. For example, hardened plastic, varying thicknesses of steel orother lightweight metals, metal alloys, composites, or the like areexamples of some of the materials that are suitable for use with thepresent invention.

The present invention may, of course, be carried out in other ways thanthose specifically set forth herein without departing from essentialcharacteristics of the invention. The present embodiments are to beconsidered in all respects as illustrative and not restrictive, and allchanges coming within the meaning and equivalency range of the appendedclaims are intended to be embraced therein.

1. Armor for a helmet comprising: an attachment having an interior pocket, the attachment being detachably mountable to the helmet; and armor disposed within the pocket of the attachment.
 2. The armor of claim 1 wherein the attachment includes an opening to allow the access to the pocket.
 3. The armor of claim 1 wherein the attachment is sealed around its periphery to encase the armor within the pocket.
 4. The armor of claim 1 wherein the attachment includes a fastener that mates with a corresponding fastener associated with the helmet.
 5. The armor of claim 4 wherein the corresponding fastener is disposed on an exterior of the helmet.
 6. The armor of claim 4 wherein the corresponding fastener is disposed on a cover that substantially surrounds the exterior of the helmet.
 7. The armor of claim 1 wherein the armor comprises flexible soft armor having one or more layers of ballistic-resistant fibers.
 8. The armor of claim 7 wherein the attachment comprises a first attachment, and further comprising a second attachment having a second pocket, the second attachment being detachably mountable to the first attachment and including a hard-armor member disposed within the second pocket.
 9. The armor of claim 8 wherein the hard armor comprises one or more hard armor plates.
 10. The armor of claim 1 wherein the attachment comprises a skirt that substantially surrounds a rear portion of the helmet.
 11. The armor of claim 1 wherein the armor comprises one or more hard-armor members.
 12. Armor for a helmet comprising: a soft-armor attachment detachably mountable to the helmet; and a hard-armor attachment detachably mountable to the soft-armor attachment.
 13. The armor of claim 12 wherein the soft-armor attachment includes a first fastener that mates with a corresponding second fastener associated with the helmet.
 14. The armor of claim 13 wherein the hard-armor attachment includes a third fastener that mates with a corresponding fourth fastener disposed on the soft-armor attachment.
 15. The armor of claim 12 wherein the soft-armor attachment encases one or more soft armor members.
 16. The armor of claim 15 wherein the one or more soft armor members comprises a flexible anti-ballistic material having one or more layers.
 17. The armor of claim 15 wherein the soft-armor attachment includes an opening to allow access to the one or more soft armor members.
 18. The armor of claim 12 wherein the hard-armor attachment encases one or more armor members.
 19. The armor of claim 18 wherein the hard-armor attachment comprises a segmented attachment wherein each segment encases a hard-armor member.
 20. The armor of claim 18 wherein the hard-armor attachment includes one or more openings to allow access to the one or more hard-armor members.
 21. The armor of claim 18 wherein the one or more armor members comprise a ceramic armor.
 22. The armor of claim 12 wherein the soft-armor attachment comprises flexible soft-armor, and the hard-armor attachment comprises one or more hard-armor members.
 23. The armor of claim 12 wherein the soft-armor attachment and the hard-armor attachment wrap substantially around at least a portion of the rear of the helmet.
 24. The armor of claim 12 wherein at least one of the soft-armor attachment and the hard-armor attachment includes an edge that is substantially parallel to a bottom edge of the helmet.
 25. A ballistic-resistant helmet comprising: a helmet that substantially surrounds a user's head; and a first attachment to encase a first ballistic-resistant member, the first attachment being detachably mountable to the helmet.
 26. The ballistic-resistant helmet of claim 25 further comprising a second attachment to encase a second ballistic-resistant member, the second attachment being detachably mountable to the first attachment.
 27. The ballistic-resistant helmet of claim 26 wherein the first attachment includes an opening to allow access to the interior of the first attachment.
 28. The ballistic-resistant helmet of claim 26 wherein the second attachment includes an opening to allow access to the interior of the second attachment.
 29. The ballistic-resistant helmet of claim 26 wherein the first ballistic-resistant member comprises a flexible soft-armor member, and wherein the second ballistic-resistant member comprises one or more hard-armor members.
 30. The ballistic-resistant helmet of claim 29 wherein the second attachment is segmented, and wherein each segment in the second attachment encases a hard-armor member.
 31. A method of enhancing the protection of a helmet comprising: forming a first attachment to include a first armor member; and disposing a fastener on the first attachment to allow the first attachment to detachably connect to the helmet.
 32. The method of claim 31 wherein the fastener on the first attachment detachably connects to a corresponding fastener associated with the helmet.
 33. The method of claim 32 wherein the corresponding fastener associated with the helmet is disposed on an exterior surface of the helmet.
 34. The method of claim 32 wherein the corresponding fastener associated with the helmet is disposed on a cover that covers at least a portion of the helmet.
 35. The method of claim 31 further comprising: forming a second attachment to include a second armor member; and disposing an additional fastener on the second attachment to allow the second attachment to detachably connect to the first attachment.
 36. The method of claim 35 wherein the additional fastener on the second attachment detachably connects to a corresponding fastener disposed on the first attachment.
 37. The method of claim 34 wherein the first armor member comprises a flexible soft-armor member, and wherein the second armor member comprises one or more hard armor members. 